Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Spinning Disc Reactors
A novel processing machine for the food and chemical industry
Flanders FOOD Technology Day 2010
IRMH ProcesstechNovel Processing Consultant
Basically a rotating disc, that can be heated or cooled, is fed with one or more liquids at its centre.
The liquids mix and spread over the disc and are collected at the edge. Mixing, heat transfer and mass transfer occurs on the disc
Flanders FOOD Technology Day 2010
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
SDRs and Food processing; key characteristics
Ability to very rapidly heat and cool fluids, especially viscous fluids; pasteurisation, fine crystal formation. Very low delta T gives less thermal damage. Film coefficients up to 50kW/m2K, overall 10kW/m2K.
Self cleaning/easy clean characteristic
Enhanced mass transfer for evaporation and odour removal with less thermal damage
Effective use of UV radiation (sunshine treated!)
Unique combination of shear and draw gives opportunities for “structure manipulation”
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
And there’s more
Fundamentally easy to scale
Surface can be catalyst coated
Surface can be modified to alter residence times
Precipitation and crystallisation can be carried out without scaling
Non foaming
Especially good at handling viscous fluids particularly in cooling heat
transfer
Pure plug flow; no back mixing
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
SDRs and viscous fluids
A unique ability to manage viscous fluids thanks to a combination of shear, draw and high temperatures.
Feed Pipe
Angular Draw
Radial Shear
Increased Area of Coverage
Rotation of Disc
Normal Entangled Polymer Drawn Disentangled Polymer
The liquid film is “drawn” which tend to align and orientate long molecules
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Removal of water (dissolved and as separate phase) from oil
Cloudy moist organicCloudy moist organicaround 1000ppm Haround 1000ppm H22OO
Clear processed organicClear processed organicaround 25ppm Haround 25ppm H22OO
SDR ProcessingSDR Processing
•• Organic heated rapidly to 200Organic heated rapidly to 200ooCC
•• Water removed with counterWater removed with counter--current current
gas flow. No spitting, no foaminggas flow. No spitting, no foaming
•• Organic cooled on walls.Organic cooled on walls.
•• Increased vapour pressure, water Increased vapour pressure, water
easily stripped with modest gas flow or easily stripped with modest gas flow or
vacuum.vacuum.
•• Exposure time short enough to avoid Exposure time short enough to avoid
degrading despite temperaturedegrading despite temperature
•• Result : Product is clear and dry.Result : Product is clear and dry.
An example of heat and mass transfer
IRMH ProcesstechNovel Processing Consultant
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SDR in the Food Industry; work carried out at Leeds University
Mayonnaise
Emulsions
Ice Cream
Fruit Juices
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Mayonnaise (70% Oil)Lemon juice, vinegar, mustard, black pepper and egg yolk were mixed and passed over the reactor disc. The temperature was increased to 30, 40, 50 and 58 oC.
Conclusion: Slowly increasing the temperature to 58 oC, could produce pasteurised, consistent, smooth and homogeneous mayonnaise .
A high viscosity and creamy mayonnaise was produced.
Salmonella test has been confirmed negative.
Particle Size Distribution
0.01 0.1 1 10 100 1000 3000
Particle Size (µm)
0
2
4
6
8
10
Volu
me (
%)
70% oil SDR mayonaise 58 C, 04/05/05 12:32:40 SDR-mayonnaise, 03/27/05 19:14:58
at 25 oCat 58 oC
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Comparison with Commercial Mayonnaise
Hellmann’s Real Mayonnaise
SDRMayonnaise
Microbiology tests confirmed that the mayonnaise was negative for Salmonella.
Aver. droplet size ~ 7 µmAver. droplet size ~ 25 µm Particle Size Distribution
0.01 0.1 1 10 100 1000 3000
Particle Size (µm)
0
2
4
6
8
10
Vo
lum
e (
%)
SDR-mayonnaise, 03/27/05 19:14:58 Hellman's mayonnaise repeat, 03/27/05 19:30:30
SDR mayonnaise is more consistent, smoother and
softer than Hellmann’s real mayonnaise.
Hellmann’sSDR
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Multiple emulsions
water (W)
an O1/W/O2
multiple emulsiona W1/O/W2
multiple emulsion
water (W2)
water (W1)
oil (O)
oil (O1)
oil (O2)
There are two distinct forms of simple multiple emulsion.
- a water-in-oil-in-water (W/O/W) and
- an oil-in-water-in-oil (O/W/O).
IRMH ProcesstechNovel Processing Consultant
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Primary Emulsion
Jet Homogenizer
primary emulsion (W/O)
oil+lipophilic emulsifier(80 vol%)
aqueous phase(20 vol%)
average droplet size ~ 0.5 -1 µm
Pressure
350 bar
Secondary Emulsionprimary emulsion
(20 vol%)Spinning disc
reactor
W+hydrophilic emulsifier aqueous phase
(80 vol%)8 ml/s,
2000 rpm
a W/O/W multiple emulsion
average droplet size ~ 2 –10 µm
Stage I
Stage II
W/O/W multiple emulsions
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
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inner aqueous phase
oil phase
primary emulsifier
secondary emulsifier
The SDR-processed multiple emulsionThe SDR-processed multiple emulsion
Confocal laser scanning microscopy
Confocal microscopy confirms that indeed mono-disperse multiple
emulsions were formed.
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Ice Cream Making Process Using SDR
Water, xanthan gum, sugar, unsalted
butter, lecithin, milk, double cream,
skimmed milk powder
Homogenisation Pasteurisation
The mix was passed continuously over the disc at
85 °C; 3000 rpm; flow rate 6 ml/s; inlet temperature 20 °C
Freezing/aeration
Model ice cream
Heated at 55 °C
0-18 hr ageing
Ice Cream Base
Samples were collected
for micro analysis
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
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Mixing(Pre-heating to 60°C)
Pasteurisation79.5°C for 15 seconds
Homogenisation
Cooling<7.2°C within 15 sec
AgeingTypical 18 hours
Conventional HTST
Freezing/aeration
The commercial process for making ice cream requires separate Pasteurisation and
Homogenisation stages followed by 18 hours ageing of the mixture.
Mixing(Pre-heating to 60°C)
Pasteurisation85°C for 0.43 seconds
Cooling<7.2°C
Balance tank0 hours
Freezing/aeration
SDR
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Challenge TestingIce cream base was spiked with E. coli K-12. The mix was passed over the SDR and
samples were collected in aseptic containers.
E. coli K-12 is a weak strain and is widely used as a model organism in research.
The samples processed at 90°C indicate that sufficient heat has been applied to achieve a reduction in microbial loading associated with a safe product.
Microbiology of Ice Cream
0
3
6
9
12
60 70 80 90
disc temperature ( oC)
E.
co
li x
10 3
(cfu
/g)
E. coli K-12
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
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ice cream base Particle Size Distribution
0.01 0.1 1 10 100 1000 3000
Particle Size (µm)
0
2
4
6
8
10
Vo
lum
e (
%)
Ian's ice cream, 06/26/07 17:18:38
Zero-hour Taste panel sample (1% lecithin), 06/26/07 17:34:51
SDR
Commercial
Particle Size Distributions
The SDR generates a stable emulsion that requires zerohours ageing to subsequently produce an ice cream product.
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Sensory Assessment of Ice Cream
Model ice cream at zero-hour ageing was found to be very acceptable to the panellists.
0
1
2
3
4
5
6
7
8
9
0 h 18 h commercial
ice cream at different ageing time
mean
valu
es
smoothness
stickness
meltability
coldness
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Pasteurisation of Fruit Juice
Prepared Fresh juice
Passed over the disc at various temperatures (75-95 °C); 2500 rpm; flow rate 6 ml/s; inlet temp. 5-10 °C
Samples were collected in aseptic containers and stored in Fridge at 5 °C
Microbiological analysis
Pasteurisation Homogenisation
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Microbiology of Fruit Juice
0
800
1600
2400
3200
4000
1 2 3 5 6 8
Time (day)
TV
C x
10
3 (c
fu/g
)
Pasteurised
Un-pasteurised
Commercial
(a)
0
200
400
600
800
1 2 3 5 6 8
Time (day)
co
lifo
rm x
10
3 (
cfu
/g)
Pasteurised
Un-pasteurised
Commercial
(b)
The spinning disc reactor using a processing temperature of 90°C achieves a microbiologically safe fruit juice.
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Sensory Assessment of Fruit Juice
The results show that the SDR technology doesn’t have detrimental effecton the perceived aroma, flavour and colour.
The SDR pasteurised juice is preferable to the commercial sample.
0
2
4
6
8
10
SDR-
Pasteurised
UnPasteurised Commercial
mea
n v
alu
es
Aroma
Flavour
Smoothness
Thickness
Colour
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
In Summary…
A controllable and scalable processor that has the potential to enhance the production of existing products and to produce unique products
Flanders’ FOOD Technology day 2010
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Akhtar, M. and Krishnan, S. S. Preparation of oil-water-oil multiple emulsions using spinning disc reactor technology, an oral presentation in the World Emulsion Congress
to be held in Lyon (France) 11-13th October (2010).Akhtar, M. Chan, P. S. K. and Dinakaran, B. S. (2010). Pasteurization of carrot juice
using spinning disc reactor technology, submitted to LWT April.Akhtar, M., Chan, P. S. K., and Clayton, G. (2010). Concentration of apple juice using spinning disc reactor technology is being considered for a patent application, University
of Leeds (2010).Akhtar, M., Blakemore, I., Clayton, G. & Knapper, S. (2009). The use of spinning disc reactor for processing ice cream base – effect of ageing in making model ice cream.
International Journal of Food Science and Technology, 44, 1139–1145.Akhtar, M., Chan, P. S. K., Clayton, G., Kanjee, U. & Koutsidis, G. (2009). Physical and chemical properties of dark chocolate processed using spinning disc reactor technology
– effects of disc temperature and residence time. Journal of Food Engineering Efficiency, 3 (1), 7-14.
Akhtar, M. (2008). Evolution in chocolate technology. Published in Food & Beverage International, February (2008) pp. 27-28.
Akhtar, M. (2008). Scientists raise the bar for greener chocolate. YORKSHIRE POST, Tuesday, 15th January, (2008).
References
IRMH ProcesstechNovel Processing Consultant
Flanders FOOD Technology Day 2010
Contacts
Ian Henderson +44 (0)1642 711227
Mahmood Akhtar + 44 (0) 1133 43 2952
Robert Addleman +44 (0) 1438 717886